Method and apparatus for shaping metals



March 31. 1925. 1,531,472

E. E. BAKER D APPARATUS FOR SHAPI Filed Oct. 10, 1921 6 III .Yllll 'To all whom it may concern:

mama Mar. 31, 1925.

UNITED srivrizs '1' 1;. Burma, or crrrcneo, rumors.

mnon m manarus son saunas p Application fled Octoher 10, 1921. Serial 110. 506,565.

Be it known that I, ERNEST E. BAKER, a citizen of the United States, residing at Chicago, in the county of Cook and State of Illinois, have invented an Improved Method and A aratus for Shaping Metals,

of which the-fgllowing is a specification The invention relates to an improved method and apparatus for shaping molten metal whereby a continuous operation in the nature of'die-casting may be accomplished to advantage.

The die-casting operation as heretofore carried out, has, so far as I am aware, been limited to the introduction of the metal to ,beformed into a stationary die or mold, in'which the metal is confined until' cool. It is obvious, therefore, that the length of the articleor product to be cast is necessarily limited. Moreover, the cost of producing articles relatively large in size is ,often prohibitive. In accordance with my invention the operation is rendered continuous by effecting relative movement between the metal as it becomes plastic and a die block or mold. Accordingly, an article of any desired or varying lengths may be produced by the same forming means.

The aim of the invention, therefore, generally stated, is to provide a method and apparatus by which a continuous shaping or casting operation may be performed with a resulting increase in the quality of'the completed product and in the efiiciency, of the operation, the cost as com ared with the benefits obtained being relatively slight.

With this aim-in view, the invention consists in the deposit of asteel alloy or other metal in molten form upon a base or support of suitable material, by introducin such metal into a die block or mold surrounding or enclosing a portion of the base, and efl'ecting relative motion between the mold and the base whereby the desired form or shape is imparted to the deposited metal as it becomes cooled and hence plastic in its passage through the mo1d.

A specific application .of the invention consists in the eposit'of a desired metal upon a. base in the form of a member or part previously formed,, in order to form an integral part thereof. This is accomplished by effecting the adhesion of the molten metal upon its introduction into the mold or die to such part, as by raising the surface temperature thereof the fusion point as it becomes enclosed by the mold. For example, a steel alloy, such as manganese steel, may be applied to a previously formed or rolled steel railroad rail,

thus providing a head of high wear-resist ing qualities.

In the accompanying drawings I have illustrated one embodiment only of myin- -vention, in connection with a rolledsteel rail, forming the base or support, to which is applied a wear-resisting surface composed of a steel alloy such as manganese steel. I desire to point out however, thatiwhile the invention is thus illustrated and herein described, it is susceptible of wide and varied usage, and various changes in the form, construction,.arrangement of the parts and mode of operation may be made without departing from the spirit and scope of-the invention as expressed in the appended claims. a

In Figure-1 of the drawings I have shown inside elevation a view-somewhat diagrammatic in character illustrating an apparatus whereby my invention may be carrled out. Fig. 2 is a transverse vertical sectional view taken in the plane of line 22 of Fig. 1.

Fig. 3 is a fragmentary longitudinal vertical sectional view .taken approximately in the plane of line 3-45 of Fig. 2. Fig. 4:

isafragmentary plan view of a portion of the apparatus.

Referring first to Figure 1, -A designates I the device 7 and prior to its passage beneath a coohng'means 11.

Any suitable means may be employed for effecting the movement of the rail A ata predetermined rate of speed throughthe device 7. HereinI have shown, by way of example, a plurality ofrolls 12, mounted upon.v horizontal axes and u on which the rail is adapted to rest. Fee ing and guidin means are provided foreng ging t t-c si e of the rail. This means may comprise a plurality of rollers 13 mounted on vertical shafts 17 the lower ends of which are geared to the horizontal drive shaft 18.

v The device? (Figs.2and 3) consists ofadw block or mold such, for example, as the member 19, made from carbon or other heat-resistgraphite or other suitable lubricant may be supplied at this point under high pressure. As shown in said figures, the portion of the passageway rearwardly of the restricted forward end is shaped so that when the rail head is in position within the die-block a space is provided between the upper surface of the rail and the upper walls 20 of the passageway, and said walls are so shaped as to form the metal introduced into the mold into a layer or strip B, of the desired exterior comformation.

Herein, the die block is supported in position by means of a suitable clamp or frame 22, having bolts 23 for engaging the sides of the block. r

The crucible8 may be of any suitable character adapted to supply a continuous stream of molten metal to the die-block. Also, any suitable means may be provided for supporting the crucible in the proper relation to the die-block.

In order to effect the adhesion of the metal poured into the die-block to the rail, or other member passing therethrough, I provide suitable heating means 9. This means, as herein shown, consists of a pair of gas burners 24, although it will be understood that any form of heating means may be employed which is capable of raising the surface temperature of the member being treated to the fusion point.

It will be understood that the speed at which the rail A passes through the dieblock 19 is determined in accordance with the time required toheat the surface thereof to the fusion point, and the rapidity with which the molten metal becomes plastic so as to be capable ofrbeing properly shaped, it being obvious that when the molten metal is introduced through the pouring slot, it immediately unites with the metal of the rail and thus adheres thereto, becoming an integral part of it. As herein shown, the rail A is made from rolled steel in the usual way, except that its head is made of less thickness, with a flattened top surface to which is applied the layer or strip B of steel alloy.

4 Preferably, the burners are of such a character as to apply an intense heat ca able of quickly penetratin to the desired epth in the time consume in its p therebethe die-block or mold constitutes a combined shaping and cooling device. Should'such chilling of the metal be insufficient, additional means may be provided for this purpose, such, for example, as the heating means 10 and the cooling means 11. The means 10 may be in the form of burners 24 and the cooling means maybe of any suitable character such as a pipe 25 connected with a source of Water supply and having jet openings arranged to discharge the cooling water onto the rail after it emerges from beneath the burners 24.

It will be apparent that a railroad rail I or other member thus provided with a hard-' ened or wear resisting surface is much su perior to the ordinary steel rail, while the cost, owing to the simplicity of the treatment, is relatively small. Indeed, from the standpoint of quality alone, such an article is superior to one constructed wholly from' the steel alloy, since only that portion of the member which receives the wear is hardened, leaving the remaining portion in a relatively softer condition, and hence. capable of-being readily bent, drilled and the like. Thus, in the case of the railroad rail, the application of the wear-resisting metal does not interfere in any way with the drilling of holes in the base v.of the rail for the reception of the connecting bolts, nor does it prevent the same from being cut or bent as desired.

When the alloy is applied to the base so as to become a part thereof, as in the case of the railroad'rail, it will be obvious that the rails are assed successively, end to end, through the e or mold, so as to render the operation continuous. Accordingly, the applied metal emerges from the mold or die in a continuous strip, and must be severed before the rails can be so arated. To ensure that the deposited meta will not cause the adhesion of the rails themselves at their adplied to articles which have become worn 1n usage, thus effecting a substantial renewal thereof.

I desire to point out especially that while I have herein shown a stationary shaping device, and a movable base or support, the invention is not. limited to this particular arrangement, for obviously the reverse arrangement may be employed if desired. Moreover, the apparatus herein shown is purelyof' an illustrative character, and its details form no essential part of the present invention.

I claim as my invention:

1 .-The method of applying-an alloy such as manganese steel to a railroad rail or other article which consists in initially heating to a fusion point the surface which is to receive the alloy, depositing molten metal onto such heated surface, confining the metal deposited on the heated surface, and then as the metal becomes plastic forming or shaping it while simultaneously cooling it to provide the desired contour to the completed article.

2. The method 'of making railway rails which consists in heating to the fusion point the substantially fiat up er surface of a rail body formed from rolled steel, then depositscribed comprising, in combination, a die blocl: having a through passageway and a filling opening in one side thereof adapted for the insertion of molten metal, means for.

effecting relative longitudinal movement between said block and a part to be treated extending through said passageway, said passageway being-shaped at one side of said opening to conform substantially to the shape of the part to be treated and at the other side of said opening providing a forming and shaping wall of substantial length spaced from the part to be treated, and means for heating said part to the fusion point immediately prior to its entrance into said passageway opposite said filling opening.

In testimony whereof, I have hereunto set my hand.

ERNEST E; BAKER. 

